Reusable frame system for home building

ABSTRACT

A building system and method of using the same may include forming a modular, collapsible, reusable frame and applying at least one sheathing layer on the modular, collapsible, reusable frame. The system and method may include applying at least one mesh layer on the at least one sheathing layer; applying at least one concrete layer on the at least one mesh layer; curing the at least one concrete layer; and removing the modular, collapsible, reusable frame. The system and method may form at least one continuous wall and roof portion to make up a monolithic structure defining an interior cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 63/298,746 filed Jan. 12, 2022, entitled “REUSABLE FRAME SYSTEM FOR HOME BUILDING” which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to a building system and method for utilizing collapsible or reusable construction structures.

BACKGROUND

Systems and methods utilized for forming structures fail to provide flexible means for constructing walls or structures in a modular manner and which prevent ease of re-use of building structures. Traditional structure construction may require a permanently installed frame and trust system to allow for construction of each wall section in the roof. Traditional systems may provide low efficiency and high-cost construction. Traditional systems may be weak with respect to insulation problems, bugs, termites, and structural strength.

SUMMARY

This summary is provided to introduce a variety of concepts in a simplified form that is further disclosed in the detailed description of the embodiments. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.

In general, the embodiments disclosed herein relate to a building system implementing a multi-layer construction to provide a high-efficiency low-cost means for building structures. The system may include a variety of layers including, but not limited to, wire mesh layers, rigid foam board, concrete layers, sheathing layers, house wrap layers, and others assembled over a reusable, collapsible, modular framing system.

Other illustrative variations within the scope of the invention will become apparent from the detailed description provided hereinafter. The detailed description and enumerated variations, while disclosing optional variations, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present embodiments and the advantages and features thereof will be more readily understood by reference to the following detailed description, appended claims, and accompanying drawings, wherein:

FIG. 1 illustrates a portion of a building system and method of using the same, according to some embodiments described herein;

FIG. 2 illustrates a portion of a building system and method of using the same, according to some embodiments described herein;

FIG. 3 illustrates a portion of a building system and method of using the same, according to some embodiments described herein;

FIG. 4 illustrates a portion of a building system and method of using the same, according to some embodiments described herein;

FIG. 5 illustrates a partially cross-sectional view of portion of a building system and method of using the same, according to some embodiments described herein;

FIG. 6 illustrates a partially cross-sectional view of portion of a building system and method of using the same, according to some embodiments described herein;

FIG. 7 illustrates a partially cross-sectional view of portion of a building system and method of using the same, according to some embodiments described herein; and

FIG. 8 illustrates a partially cross-sectional view of portion of a building system and method of using the same, according to some embodiments described herein.

The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

DETAILED DESCRIPTION

The specific details of the single embodiment or variety of embodiments described herein are to the described system or methods of use. Any specific details of the embodiments are used for demonstration purposes only and no unnecessary limitations or inferences are to be understood from there.

It is noted that the embodiments reside primarily in combinations of components and procedures related to the system. Accordingly, the system and components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

The specific details of the various embodiments described herein are used for demonstration purposes only, and no unnecessary limitation or inferences are to be understood therefrom. Furthermore, as used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship, or order between such entities or elements.

In general, a building system as disclosed herein may include a building system including a collapsible frame. As used herein, “collapsible” may include any variations in structure and systems that are collapsible, dis-assemblable, modular, foldable, or otherwise capable of being reduced in size for ease of storage, travel, and use. The building system may allow for a faster, less expensive, and more structurally sound structure to be built. The building system may be constructed and arranged to facilitate building a structure that may be hurricane resistant, termite proof, bug proof, hollow-monolithic, and highly insulated.

In general, a building system as disclosed herein may include at least a portion of a structure assembled via a modular frame including any number of beams, tubes, joint, or connections to form an approximate frame shape of a structure to be constructed. The frame may be a reusable, collapsible assembly of various structural members and connections configured to form walls, trusses, roof lines, roofs, doors, or the like. According to some embodiments, the building system may include a collapsible frame system having structural members constructed in a scissor-like arrangement and which may be expandable and supported by external supports, hydraulics, beams, or the like. In this way, multiple story or multiple floor structure may be designed and manufactured. Structural members may include members comprising materials such as, but not limited to, wooden beams, metal poles or pipes, composite members, or the like.

Structural members may comprise wood, metal, rebar, plastic, structural insulated panels, sprayed polystyrene, or expanded polystyrene panels. Connections may include connectors such as metallic, plastic, composite, or would connections or mechanical fasteners constructed and arranged to connect structural members together to form various components of a reusable and collapsible frame. According to some embodiments, various portions of the modular frame may be on collapsible supports or casters, including wheels, such that portions of the frame, such as a roof portion, are easily supported during use and collapsible after use. One of ordinary skill in the art will understand and appreciate that the disclosed system may allow for the construction of various structures including any number of walls, floors, ceilings, and roof or roof portions. According to some embodiments, the disclosed system may allow for the construction of individual walls, roofs, or the like separate from one another prior to assembly.

The modular frame may be assembled on a prefabricated slab or pre-formed basement, or the like. According to some embodiments, multiple modular frames may be combined to form the desired structure having at least one or multiple floors. According to some embodiments, the same frame may be used multiple times on the same site location to make the structure larger vary the shape of the structure.

In general, a building system as disclosed herein may include optionally applying a sheathing such as rubber, polystyrene, polyurethane, structural insulated panels, expanded polystyrene panels, hardboard, engineered wood, plywood, or metal paneling to cover the modular frame as disclosed above.

In general, a building system as disclosed herein may include optionally applying a mesh layer or structural wrap, such as a house wrap, to cover the sheathing as disclosed above.

In general, a building system as disclosed herein may include applying at least one layer of concrete, such as via spraying, to form a multi-layer structure including a layer of sheathing, house wrap, mesh, and cured concrete.

Subsequently, the modular frame may be collapsed or deconstructed to provide a structure. According to some embodiments, additional layers of sheathing, house wrap, mesh, or concrete may be applied before or after removal of the modular frame to provide an enhanced strength structure. Additional layers may be applied including providing a rigid foam insulation or stucco to the structure.

According to some embodiments, a building system as disclosed herein may include applying a first mesh layer to cover a frame as disclosed above. According to some embodiments, the wire mesh may be a steel wire mesh.

The building system as disclosed herein may include applying a rigid foam board layer over the first wire mesh layer. A second wire mesh layer may be applied over the opposite side of the rigid foam board layer and subsequently joining the first wire mesh layer and the second wire mesh layer by passing at least one connector through the rigid foam board layer at securing it to the first wire mesh layer and wire mesh layer, such as via weld.

In general, a building system as disclosed herein may include applying at least one layer of concrete, such as via spraying, to form the exterior of a multi-layer structure. The building system as disclosed herein may include applying at least one layer of mortar, such as via trowel or spraying, to form the interior of a multi-layer structure

Subsequently, the modular frame may be collapsed or deconstructed to provide a structure. According to some embodiments, additional layers of sheathing, house wrap, mesh, or concrete may be applied before or after removal of the modular frame to provide an enhanced strength structure. Additional layers may be applied including providing a rigid foam insulation or stucco to the structure.

According to some embodiments, a system for building a structure may include a modular frame with a mesh disposed thereon. A plurality rigid foam board layers may be positioned over the mesh. According to some embodiments, a first foam board layer may be placed over the mesh, a discontinuous second foam board layer may be placed over first form board layer, and a third foam board layer may be placed over the discontinuous second foam board layer. In this way, a plurality of voids may be defined by the combination of the first, second, and third foam board layers at positions where the second foam board layer is discontinuous. Subsequently, the at least one void or plurality of voids may be filled with concrete to form a structural support therein.

As shown in FIGS. 1-6 , a building system and method is provided. A modular frame 100 may be an assembly of various structural members 100 and 16 temporarily connected to one another via connection members 114. The modular frame 100 may include a first wall 102, a second wall 104, a third wall 106, a fourth wall 108, and at least one roof portion 110, 112. One of ordinary skill in the art will understand that the simplified 4 wall trust roof frame shown in figure one is purely illustrative and various arrangements of walls and roofs are contemplated by this disclosure. As shown in FIGS. 1-6 , the building system and method may provide means for incorporating various roofs, ceilings, floors, walls, doors, windows, or thru-ways as desired.

As best seen in FIG. 2 , the building system and method 200 may include applying sheathing including a number of sheathing panels 202, 204, 206, 208, and 210 configured to encapsulate the modular frame as best seen in FIG. 1 . The sheathing panels 202, 204, 206, 208, and 210 may abut or overlap adjacent panels at seams 212.

As best seen in FIG. 3 , the building system and method 300 may include optionally applying a house wrap and mesh layer 310 to at least one of various walls 302, 304 or roofing 306. According to some embodiments, both a house wrap and mesh layer may be applied over the sheathing as seen in FIG. 2 either in combination or individually.

As best seen in FIG. 4 , the building system and method 400 may include applying a layer of concrete 410 to at least one of various walls 402, 404 or roofing 406. According to some embodiments, the layer of concrete 410 may be applied, such as via spraying, over the house wrap and mesh layer as best seen in FIG. 3 .

Application of the sheathing, house wrap, mesh layer, and concrete layer may occur multiple times over one another to provide a plurality of layers making up the building system.

As best seen in FIG. 5 , a partial cross-sectional view of a building system and method 500 may include a collapsible, reusable modular frame 502 onto which a first sheathing 504 a, first house wrap layer and first mesh layer 506 a, and first concrete layer 508 a may be applied. The collapsible, reusable modular frame 502 may subsequently be removed. Alternatively, a second sheathing 504 b, a second mesh layer 506 b, and second concrete layer 508 b may be applied over the first sheathing 504 a, first house wrap layer and first mesh layer 506 a, and first concrete layer 508 a to further strengthen the structure. According to some embodiments, a second mesh layers 506 b may not be utilized. The collapsible, reusable modular frame 502 may subsequently be removed.

As best seen in FIG. 6 , a partial cross-sectional view of a building system and method may include a first sheathing 604 a, first house wrap layer and first mesh layer 606 a, and first concrete layer 608 a. The building system and method may include a second sheathing 604 b, a second house wrap layer and second mesh layer 606 b, and second concrete layer 608 b. In this way, the building system and method may provide a robust structure including at least one joined wall and roof portion to define an interior 610.

As best seen in FIG. 7 , a partial cross-sectional view of a building system and method 500 may include a collapsible, reusable modular frame 502 onto which a first wire mesh 700 may be secured. Subsequently, a rigid foam board layer 702 may be overlayed onto the first wire mesh 700. A second wire mesh 706 may be overlayed onto the rigid foam board layer 702. The first wire mesh 700 and the second wire mesh 706 may be secured to one another by passing a plurality of connectors 704 through the rigid foam board layer 702 and securing the plurality of connectors 704 to the first wire mesh 700 and the second wire mesh 706. A layer of concrete 708 may be applied over the second wire mesh 706 to form a multi-layer structure. The collapsible, reusable modular frame 502 may subsequently be removed.

As best seen in FIG. 8 , a partial cross-sectional view of a building system and method may include a reusable modular frame 502 onto which a first wire mesh 700 may be secured. Subsequently, a rigid foam board layer 702 may be overlayed onto the first wire mesh 700. A second wire mesh 706 may be overlayed onto the rigid foam board layer 702. The first wire mesh 700 and the second wire mesh 706 may be secured to one another by passing a plurality of connectors 704 through the rigid foam board layer 702 and securing the plurality of connectors 704 to the first wire mesh 700 and the second wire mesh 706. A layer of concrete 708 may be applied over the second wire mesh 706 to form a multi-layer structure.

The following description of variants is only illustrative of components, elements, acts, products, and methods considered to be within the scope of the invention and are not in any way intended to limit such scope by what is specifically disclosed or not expressly set forth. The components, elements, acts, products, and methods as described herein may be combined and rearranged other than as expressly described herein and are still considered to be within the scope of the invention.

According to variation 1 a building system for forming at least one to-be-constructed structure may include a modular, collapsible, reusable frame; at least one sheathing layer disposed on the modular, collapsible, reusable frame; at least one house wrap layer disposed on at least a portion of the at least one sheathing layer; at least one mesh layer disposed on the at least one house wrap layer; at least one concrete layer disposed on the at least one mesh layer; and wherein the at least one sheathing layer, the at least one mesh layer, and the at least one concrete layer form at least one wall, roof, floor, or ceiling portion.

Variation 2 may include a system as in variation 1, further including a plurality rigid foam board layers spaced from one another to form at least one void therein, the at least one void being filled with concrete to form a vertical support therein.

Variation 3 may include a system as in any of variations 1 through 2, wherein the modular, collapsible, reusable frame includes at least one structural member and at least one connection member.

Variation 4 may include a system as in any of variations 1 through 3, wherein the at least one structural member includes at least one of wooden beams, metal poles, pipes, composite members, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.

Variation 5 may include a system as in any of variations 1 through 4, wherein the at least one connection member includes at least one of, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.

Variation 6 may include a system as in any of variations 1 through 5, wherein the modular, collapsible, reusable frame includes a plurality of structural members and a plurality of connection members.

Variation 7 may include a system as in any of variations 1 through 6, wherein the modular, collapsible, reusable frame includes at least one first wall, at least one second wall, at least one third wall, at least one fourth wall, and at least one roof portion.

Variation 8 may include a system as in any of variations 1 through 7, wherein the at least one sheathing layer includes at least one of Masonite, rubber, polystyrene, polyurethane, structural insulated panels, expanded polystyrene panels, hardboard, engineered wood, plywood, or metal paneling.

Variation 9 may include a system as in any of variations 1 through 8, further including at least one insulation layer disposed on the at least one concrete layer.

Variation 10 may include a system as in any of variations 1 through 9, further including at least one stucco layer disposed on the at least one insulation layer.

Variation 11 may include a system as in any of variations 1 through 10, further including a second sheathing layer disposed on the at least one concrete layer; a second mesh layer disposed on the second sheathing layer; and a second concrete layer disposed on the second mesh layer.

Variation 12 may include a system as in any of variations 1 through 11, further including at least one insulation layer disposed on the second concrete layer.

Variation 13 may include a system as in any of variations 1 through 12, further including at least one stucco layer disposed on the at least one insulation layer.

According to variation 14, a building system for forming at least one to-be-constructed structure including a reusable modular frame; a first wire mesh overlayed onto the reusable modular frame; a rigid foam board layer overlayed onto the first wire mesh; a second wire mesh overlayed onto the rigid foam board layer; and a layer of concrete overlayed onto the second wire mesh to form a multi-layer structure. According to some embodiments, a layer of mortar may be overlayed onto the first wire mesh to form a multi-layer structure.

Variation 15 may include a building system for forming at least one to-be-constructed structure as in variation 14, further including a plurality of connectors passed through the rigid foam board layer and constructed and arranged to fix the first wire mesh to the second wire mesh.

Variation 16 may include a building system for forming at least one to-be-constructed structure as in variation 14 or 15, wherein the reusable modular frame includes at least one structural member and at least one connection member.

Variation 17 may include a building system for forming at least one to-be-constructed structure as in any of variations 14 through 16, wherein the at least one structural member includes at least one of wooden beams, metal poles, pipes, composite members, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.

Variation 18 may include a building system for forming at least one to-be-constructed structure as in any of variations 14 through 17, wherein the at least one connection member includes at least one of, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.

Variation 19 may include a building system for forming at least one to-be-constructed structure as in any of variations 14 through 18, wherein the reusable modular frame includes a plurality of structural members and a plurality of connection members.

Variation 20 may include a building system for forming at least one to-be-constructed structure as in any of variations 14 through 19, wherein the modular, collapsible, reusable frame includes at least one first wall, at least one second wall, at least one third wall, at least one fourth wall, and at least one roof portion.

Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to describe and illustrate every combination and subcombination of these embodiments. One of ordinary skill in the art will understand and appreciate that the disclosed system may allow for the construction of various structures including any number of walls and roof or roof portions. According to some embodiments, the disclosed system may allow for the construction of individual walls, roofs, or the like prior to assembly. Accordingly, all embodiments can be combined in any way and/or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.

An equivalent substitution of two or more elements can be made for any one of the elements in the claims below or that a single element can be substituted for two or more elements in a claim. Although elements can be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that at least one element from a claimed combination can in some cases be excised from the combination and that the claimed combination can be directed to a subcombination or variation of a subcombination.

It will be appreciated by persons skilled in the art that the present embodiment is not limited to what has been particularly shown and described hereinabove. A variety of modifications and variations are possible in light of the above teachings without departing from the following claims. 

I/we claim:
 1. A building system for forming at least one to-be-constructed structure, comprising: a modular, collapsible, reusable frame; at least one mesh layer disposed; and at least one cement layer disposed on the at least one mesh layer; and wherein, the at least one mesh layer and the at least one cement layer form at least one joined wall and at least one roof portion to define an interior cavity.
 2. A building system for forming at least one to-be-constructed structure as in claim 1, further comprising; a plurality rigid foam board layers spaced from one another to form at least one void therein, the at least one void being filled with concrete to form a vertical support therein.
 3. A building system for forming at least one to-be-constructed structure as in claim 1, wherein the modular, collapsible, reusable frame comprises at least one structural member and at least one connection member.
 4. A building system for forming at least one to-be-constructed structure as in claim 4, wherein the at least one structural member comprises at least one of wooden beams, metal poles, pipes, composite members, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.
 5. A building system for forming at least one to-be-constructed structure as in claim 4, wherein the at least one connection member comprises at least one of, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.
 6. A building system for forming at least one to-be-constructed structure as in claim 1, wherein the modular, collapsible, reusable frame comprises a plurality of structural members and a plurality of connection members.
 7. A building system for forming at least one to-be-constructed structure as in claim 1, wherein the modular, collapsible, reusable frame comprises at least one first wall, at least one second wall, at least one third wall, at least one fourth wall, and at least one roof portion.
 8. A building system for forming at least one to-be-constructed structure as in claim 1, wherein the at least one sheathing layer comprises at least one of rubber, polystyrene, polyurethane, structural insulated panels, expanded polystyrene panels, hardboard, engineered wood, plywood, or metal paneling.
 9. A building system for forming at least one to-be-constructed structure as in claim 1, further comprising at least one insulation layer disposed on the at least one cement layer.
 10. A building system for forming at least one to-be-constructed structure as in claim 9, further comprising at least one stucco layer disposed on the at least one insulation layer.
 11. A building system for forming at least one to-be-constructed structure as in claim 1, further comprising: a second sheathing layer disposed on the at least one cement layer; a second mesh layer disposed on the second sheathing layer; and a second cement layer disposed on the second mesh layer.
 12. A building system for forming at least one to-be-constructed structure as in claim 11, further comprising at least one insulation layer disposed on the second cement layer.
 13. A building system for forming at least one to-be-constructed structure as in claim 12, further comprising at least one stucco layer disposed on the at least one insulation layer.
 14. A building system for forming at least one to-be-constructed structure, comprising: a reusable modular frame; a first wire mesh overlayed onto the reusable modular frame; a rigid foam board layer overlayed onto the first wire mesh; a second wire mesh overlayed onto the rigid foam board layer; and a layer of concrete overlayed onto the second wire mesh to form a multi-layer structure.
 15. A building system for forming at least one to-be-constructed structure as in claim 14, further comprising a plurality of connectors passed through the rigid foam board layer and constructed and arranged to fix the first wire mesh to the second wire mesh.
 16. A building system for forming at least one to-be-constructed structure as in claim 14, wherein the reusable modular frame comprises at least one structural member and at least one connection member.
 17. A building system for forming at least one to-be-constructed structure as in claim 16, wherein the at least one structural member comprises at least one of wooden beams, metal poles, pipes, composite members, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.
 18. A building system for forming at least one to-be-constructed structure as in claim 16, wherein the at least one connection member comprises at least one of, wood, metal, rebar, plastic, structural insulated panels, or expanded polystyrene panels.
 19. A building system for forming at least one to-be-constructed structure as in claim 14, wherein the reusable modular frame comprises a plurality of structural members and a plurality of connection members.
 20. A building system for forming at least one to-be-constructed structure as in claim 14, wherein the modular, collapsible, reusable frame comprises at least one first wall, at least one second wall, at least one third wall, at least one fourth wall, and at least one roof portion. 